Rotary Knob Encoder for Deadbolt Position Tracking
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Solution Overview
Problem
Existing deadbolt locks lack accurate reporting of rotational position for manual and automatic actuation, leading to potential over-driving or under-driving of the bolt, which can cause damage or incorrect locking states.
Innovation Solution
A rotary knob with a cantilevered beam and circuit board configuration that includes signal traces, allowing the controller to determine the rotational position through electrical contact, enabling precise tracking of the bolt's state and preventing damage by constraining the rotational range and using a motor with a clutch mechanism for non-manual actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a motor is added for automatic actuation, then automation capability is improved, but device complexity increases
Solution Approach 1:
The patent combines manual and automatic actuation mechanisms into a single integrated deadbolt system. The motor assembly integrates with the existing manual crank mechanism, allowing both manual operation and automatic motor-driven operation through a unified system architecture.
Solution Approach 2:
A clutch mechanism serves as an intermediary between the motor and the drive train. The clutch engages or disengages the motor from the drive train based on operational mode, allowing automatic actuation when engaged and manual operation when disengaged, thereby managing complexity through controlled coupling.
2Measurement precision
If rotational position tracking is implemented, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical position sensing mechanisms with an optical encoder system. The optical encoder uses light-based detection to determine rotational position, eliminating the need for complex mechanical switches or potentiometers while achieving high measurement precision.
Solution Approach 2:
The optical encoder creates an optical copy or representation of the rotational position through coded disks and light sensors. This allows precise position tracking by detecting the position of light patterns rather than direct mechanical contact, reducing wear and complexity.
3Ease of operation
If the knob is made rotatable for manual operation, then ease of operation is improved, but reliability deteriorates due to potential over-driving
Solution Approach 1:
The optical encoder provides continuous feedback on the rotational position of the knob and drive train. This feedback allows the system to monitor and control the actuation process, preventing over-driving by detecting when the bolt reaches its extended or retracted position and stopping motor rotation accordingly.
Solution Approach 2:
The system allows the knob to rotate freely for manual operation but uses the optical encoder to detect only the necessary portion of rotation required for proper bolt positioning. This enables ease of manual operation while ensuring reliable positioning by tracking only the critical rotational range.
Data Source
AI summary
A rotary knob for operating an electronically actuable deadbolt is described herein. According to some embodiments, the rotary knob includes a chassis, an outer wall rotatably coupled to the chassis about a central axis of the knob, a cantilevered beam attached to an inner surface of the outer wall and extending towards the central axis of the knob such that the beam is configured to rotate with the outer wall about the central axis, a circuit board coupled to the chassis, the circuit board including signal traces, and an electrical contact extending from the cantilevered beam in a direction toward the signal traces and electrically connectable with the signal traces. A controller of the rotary knob is configured to determine a position of the deadbolt based on at least the state of the electrical connection between the electrical contact and the signal traces.